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CYLINDER HEAD/CYLINDER/PISTON

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

- Using the set of feeler gauges, measure the

clearance of each valve.

Clearances:

• 0.12 ± 0.02 mm at the intake.
• 0.12 ± 0.02 mm at the exhaust.

- If the clearance is not correct, adjust by means

of the cam follower screw.

Checking the valve clearance

• At the intake a 0.15 mm feeler gauge

shouldn't go.

• At the exhaust a 0.15 mm feeler gauge

shouldn't go.

- On the contrary, if the fealer gauge goes, reset

the clearances.

Содержание XS1P52QMI-4

Страница 1: ...Sales division Technical network leadership WORKSHOP MANUAL 125 151 CC 4 STROKE ENGINE 2 VALVES SYM...

Страница 2: ......

Страница 3: ...n cover 11 Removal of the drive pulley 11 Removal of the driven pulley 12 Changing the drive pulley bearings 12 Checking the drive belt 12 Removal of the clutch lining assembly 13 Refitting the clutch...

Страница 4: ...he cylinder head 29 Removal of the camshaft and or rockers 32 Removal of the valves or valve stem seals 33 Removal of the cylinder piston 35 Checking the cylinder 36 Checking the piston 36 Checking th...

Страница 5: ...ppropriate clothing such as a cotton overall Do not breath fumes Explosive The product can explode under certain circumstances flame heat impact friction Avoid impacts friction sparks and heat Hazardo...

Страница 6: ...e to the vehicle and in certain cases a cancellation of the warranty can be involved if the recommendations are not fully respected Note Operation that can be difficult Indicate a note which gives key...

Страница 7: ...8 2 mm Cubic capacity 124 6 cc 150 6 cc Max power output 6 5 kW at 7500 rpm 7 7 kW at 7500 rpm Max torque rating 9 Nm at 6000 rpm 10 6 Nm at 6000 rpm Compression 11 8 bars at 380 rpm 7 bars Minimum Lu...

Страница 8: ...ed to run on 95 or 98 unleaded fuel only Never run the machine with a petrol oil mixture Fuel pipes must absolutely be changed if there are any signs of wear cracks etc The clips are specific they mus...

Страница 9: ...ead cover 10 Nm Camshaft gear 12 Nm Valve clearance covers 10 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Cylinder casings 12 Nm RH casing cov...

Страница 10: ...ith 64765 Engine mount 802349 756668 Lip seal push tool 750016 Flywheel pul ler 757990 Lip seal push tool 752237 Adjustable pin wrench 758008 Clutch com pression tool 752361 801682 752361 39 mm pipe w...

Страница 11: ...st P N 500140 Set of shims Slide calipers Multimeter Heat gun Automatic resetting type torque wrench 5 to 25 Nm Type Facom R 306A25 Intertia type extractor tool for bearings from 6 to 18 mm Type Facom...

Страница 12: ...Put the assembly on stand P N 064765 clamped in the jaws of a vice Changing the engine oil To drain the engine remove the cap and let the oil drip Tightening torque 20 Nm Replace the seal each time yo...

Страница 13: ...on cover Remove the transmission cover 8 screws Remove the paper gasket and the two 2 centering pins Tightening torque 10 Nm Removal of the drive pulley Hold the fixed flange with tool P N 752237 Remo...

Страница 14: ...drum and the clutch and drive pulley assembly Tightening torque 45 Nm Changing the drive pulley bearings Remove the holder 1 and its 3 plastic guides 2 Remove the moving flange 4 6 bearings 3 The bea...

Страница 15: ...espect the way the rollers are installed Grease the moving flange bore lightly high temperature grease Removal of the clutch lining assembly Using the depth calliper measure the thickness of the clutc...

Страница 16: ...rease the governor seat 3 pins 6 high temperature grease and assemble the parts in reverse order to removal Compress the clutch and driven pulley assembly using tool 758008 equipped with the protectio...

Страница 17: ...Removal of the starter system Remove the plate 7 screws Actuate the kick starter gear sector 1 by hand and remove the kick starter drive piece 2 and washer Remove the lock ring 3 using circlip pliers...

Страница 18: ...Hook the second buckle B of the spring onto the starter gear sector Wind the spring so as to position the kick starter sector on the stop C of the cover Turn over the cover fit the washer and the cir...

Страница 19: ...relay box Tightening torque 10 Nm Use a drip pan to catch the transfer box oil when the cover is removed Remove the secondary transmission cover 7 screws Tightening torque 22 Nm Remove the paper gask...

Страница 20: ...and 90 C Use an inertia type extractor tool to remove the bearings While the casing is expanded fit the new bearing fully home in its housing Using fitting tool P N 757990 fit a new lightly greased g...

Страница 21: ...of Peugeot Motocycles CARBURETTOR Removal of the carburettor Disconnect the vacuum hose Loosen the collar Remove the carburettor Removal of the choke Remove the choke cap Locate the position of the c...

Страница 22: ...screws Remove the spring Remove the needle valve and membrane assembly Remove the needle stop 2 and its spring 3 by pulling it out Remove the needle and its washer 4 The height oif the needle is fact...

Страница 23: ...consent of Peugeot Motocycles Remove the float 6 pin 5 Remove the float and the needle valve Remove the idle jet 7 Remove the main jet 8 Remove the needle well 9 Check the condition of the needle valv...

Страница 24: ...Turn clockwise the mixture control screw 1 while counting the number of turns until it is screwed home When re fitting this operation allows you to put it back to its initial adjustment position Remo...

Страница 25: ...ondition Clean the carburettor body with Biosane cleanser ref 754748 or use an ultrasonic cleaning tank Blow into every jet and duct of the carburettor body with compressed air Do not use any metal to...

Страница 26: ...o remove the magneto flywheel Remove the carburettor Remove the inlet coupling 2 nuts Tightening torque 10 Nm Remove the plastic spacer The paper gasket must be changed each time it is removed Remove...

Страница 27: ...e pin wrench P N 752237 Remove the nut and the washer Tightening torque 45 Nm Tighten flywheel extractor P N 750016 on the rotor Lock the flywheel extractor and turn the thrust bolt until the rotor is...

Страница 28: ...mm C Screw Length 100 mm Remove the RH cover Tightening torque 12 Nm Remove the paper gasket 1 and the 2 locating pins 2 Remove the starter ring 3 Remove the starter dog 4 Using pin spanner ref 752237...

Страница 29: ...Checking the overrunning clutch Rotate the overrunning clutch by hand It must rotate in direction A It must be block in direction B If it doesn t replace the overrunning clutch Replacing the lip seal...

Страница 30: ...L FREEWHEEL 28 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Remove the circlip 1 Remove the oil pump gear 2 Remove the pin Remove the oil pum...

Страница 31: ...e paper gasket must be changed each time it is removed Removal of the cylinder head Remove the pneumatic valve 1 Remove the volute 2 6 screws Remove the cylinder cover Right side 3 4 screws Disconnect...

Страница 32: ...itten consent of Peugeot Motocycles Removal of the chain tensioner plug 4 Remove the O ring Using a screwdriver slacken the chain tensioner 5 Removal of the chain tensioner Remove the camshaft gear 6...

Страница 33: ...without the written consent of Peugeot Motocycles Remove the 2 bolts 7 Gradually loosen in a crosswise order the 4 nuts which secure the cylinder head 8 Remove the 4 nuts Remove the plate 9 Remove the...

Страница 34: ...tten consent of Peugeot Motocycles Removal of the camshaft and or rockers Remove the cylinder head Remove the stopper plate 1 Tightening torque 10 Nm Remove the pins from the rockers using a 5 mm scre...

Страница 35: ...Compress the spring of one of the valves using the valve lifter P N 754035 Remove the 2 half cones 1 Uncompress the spring and remove the tool Remove The upper cup 2 The spring 3 The valve 4 The valv...

Страница 36: ...o the cup forcefully with the tool when decompressing the spring When re installing the rocker pins position the indentation of the axles towards the outside of the cylinder head to fit the cylinder s...

Страница 37: ...t the written consent of Peugeot Motocycles Removal of the cylinder piston Remove the cylinder head Remove the chain guide pad 1 Remove the cylinder Remove the base gasket 2 and the 2 centring pillars...

Страница 38: ...iston The piston should show no traces of scoring or seizure The rings must be free in their grooves Measure the piston diameter at 9 mm from the piston skirt 125 cc 151 cc Piston diameter 52 385 to 5...

Страница 39: ...cial direction Fit the 2 piston rings 2 on each side of the spring offsetting the gap of each ring no special direction Install the compression ring 3 by placing the 2R mark upwards Install the top co...

Страница 40: ...ing gap Install the cylinder base gasket and the 2 guiding pillars on the crankcase When refitting the cylinder we recommend locking the piston using the fork part number 756575 in order to facilitate...

Страница 41: ...ng torque 20 Nm Fit and tighten the 2 fixing bolts 6 Tightening torque 12 Nm Setting the timing Turn the magnetic wheel to line up the T mark with the the crankcase boss A Fit the timing chain on the...

Страница 42: ...Tightening torque 8 Nm Checking the timing Rotate the engine twice 2 revolutions in the engine s operating direction Turn the magnetic wheel to line up the T mark with the the crankcase boss A Make s...

Страница 43: ...measure the clearance of each valve Clearances 0 12 0 02 mm at the intake 0 12 0 02 mm at the exhaust If the clearance is not correct adjust by means of the cam follower screw Checking the valve clear...

Страница 44: ...rrunning clutch Remove the cylinder and the piston Remove the starter motor 2 screws Tightening torque 10 Nm Remove the 2 screws that secure the RH half casing Remove the RH casing Remove the 2 centri...

Страница 45: ...end side play The maximum side play on the conrod end must not exceed 0 55 mm The out of round values measured on the ends of the crank should not exceed 0 1 mm and must be measured 80 mm from the tra...

Страница 46: ...he conrod and crankshaft assembly Position the LH casing horizontally Fit the timing chain 2 through the timing well Fit the conrod and crankshaft assembly into the LH crankcase Fit the 2 guiding bush...

Страница 47: ...KCASE 45 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Fit and tighten the 2 clamping bolts Tightening torque 12 Nm Trim the casing gasket in...

Страница 48: ...P N MA0020GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC APV 06 2010 non contractual pictures...

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